Total prism mold seamless combination mechanism and method

Abstract

The seamless combination mechanism comprises a table top and fastening tools, the fastening tools are symmetrically arranged on the table top, template areas are arranged in the fastening tools, a combination area is arranged between the fastening tools, an observation window is formed in the table top, and the observation window is matched with the combination area. By means of the design, the seamless combined die for the thin plates is achieved, the production period is short, and meanwhile the quality is high. Thin plate combination is adopted, and the copying and processing period is shortened. And meanwhile, the influence of machining stress can be avoided, the quality is guaranteed, and the market period of products is shortened.

Description

Technical Field

[0001] The present invention relates to the field of prism technology, and in particular to a full prism mold seamless assembly mechanism and method. Background Art

[0002] At present, the requirements for engraving full prism templates are relatively high. The engraving process of micro-prisms has a long cycle and extremely strict requirements on the engraving environment and tools. The wear of tools and other problems affect the processing accuracy. If the tool is changed or the machine is stopped in the middle, the position will be slightly offset during the operation and cannot completely match the previous tool path. Therefore, in the actual processing process, the area of ​​the prism matrix cannot reach a relatively large specification, and the area of ​​the mold can only be increased by combination. In the process of increasing the area, it is usually made by making a thicker template, flattening the back surface, and then combining it.

[0003] However, the production cycle of thick templates is long and it is difficult to keep up with market changes. If the electroforming stress is not adjusted properly, it will cause premature separation and damage the original mold. At the same time, the thick plate will still form processing stress during the later cutting, trimming, and fine grinding processes. The stress concentration will cause cracks between the substrate and the replica workpiece, and the liquid will be absorbed, damaging the original mold and the replica.

[0004] The thin plate combination has a short production cycle and is easy to process. However, after the thin plate is separated from the original mold, the plate surface will bend due to the force or stress during operation and processing, and the prism surface will be curved. During the combination process, the two cannot be consistent, resulting in differences in transition and lack of integrity.

[0005] Therefore, it is necessary to improve the above problems. Summary of the invention

[0006] Aiming at the defects of the prior art such as long production cycle and poor mold quality, the present invention provides a new full prism mold seamless combination mechanism and method.

[0007] In order to solve the above technical problems, the present invention is implemented by the following technical solutions:

[0008] A seamless assembly mechanism for a full prism mold comprises a table top and a fastening tool, wherein the fastening tool is symmetrically arranged on the table top, a template area is arranged inside the fastening tool, a assembly area is arranged between the fastening tool, and the table top is provided with an observation window, which cooperates with the assembly area.

[0009] The template area is used to place the templates to be assembled, and the fastening tooling is used to fasten the templates to be assembled. The templates to be assembled are made of thin plates. The assembly area is used to assemble two templates to be assembled. The observation window is used to observe the templates to be assembled to ensure the accuracy of alignment and welding. The stability of the templates to be assembled during the processing is ensured by using the cooperation of the table and the fastening tooling. The fastening tooling is symmetrically arranged on the table, providing uniform support and clamping force to ensure the precise alignment of the templates to be assembled during the assembly process.

[0010] The present invention realizes a thin plate seamless combination mold through the above design, which has a short production cycle and high quality. The present invention adopts a thin plate combination to shorten the replication and processing cycle. It protects the original mold and avoids the influence of processing stress, ensures quality, and shortens the product launch cycle.

[0011] Preferably, in the above-mentioned seamless assembly mechanism of a full prism mold, the fastening tooling comprises reference blocks arranged in parallel up and down, and a template area is formed between the reference blocks.

[0012] The datum blocks ensure accurate positioning of the template in the fastening fixture, improving the consistency and repeatability of template placement. The parallel setting of the datum blocks simplifies the template installation process, allowing the template to be quickly and easily placed in the fastening fixture. The parallel structure of the datum blocks provides uniform support and enhances the overall stability and durability of the fastening fixture. The design of the datum blocks helps to evenly distribute stress during processing and reduce template deformation caused by stress concentration.

[0013] Preferably, in the above-mentioned seamless assembly mechanism of full prism mold, tightening threaded holes are symmetrically arranged on both sides of the reference block, and the reference blocks are threadedly connected.

[0014] Threaded connections provide a stable and adjustable connection method, which enhances the structural stability of the fastening tooling when clamping the template. Through threaded connections, the distance between the reference blocks can be accurately adjusted to adapt to templates of different thicknesses, ensuring the flatness of the template and the accuracy of the combination. Threaded connections allow the reference blocks to clamp the template evenly, ensuring that the template remains parallel during processing. Compared with other connection methods, threaded connections have higher durability and reliability, and are suitable for long-term and repeated use. Threaded connections can adjust the pressure according to processing requirements to adapt to template processing of different materials and thicknesses.

[0015] Preferably, in the above-mentioned seamless combination mechanism of full prism mold, the table top is a magnetic table top, and the fastening tool is magnetically connected to the table top.

[0016] The magnetic connection allows the fastening tooling to be quickly and easily positioned and fixed on the table, which improves work efficiency, simplifies the installation and adjustment process of the fastening tooling, and makes the operation easier. The magnetic connection also facilitates the position adjustment of the fastening tooling, which is convenient for the template to be aligned close.

[0017] Preferably, in the above-mentioned seamless combination structure of a full prism mold, the template areas extend toward each other into the combination area.

[0018] The design of the template areas extending into the assembly area in opposite directions helps to ensure the accurate docking of the templates during assembly, improves the assembly accuracy of the entire mold, and is also conducive to the grinding of the templates before assembly.

[0019] A method for seamlessly assembling a full prism mold, comprising any one of the seamless assembly mechanisms described above, and further comprising the following steps:

[0020] S1: Make the template, and add at least 10cm of margin area around the original mold during production;

[0021] S2: cutting the cutting area and the combined edge position of the template to obtain the template to be combined;

[0022] S3: Use fastening tools to clamp and flatten the template to be assembled;

[0023] S4: fine grinding the combined edge of the combined template;

[0024] S5: Bring the fastening fixtures closer, align the combined edges of the two templates to be combined, and use laser to perform seam welding on the back to obtain a seamless mold.

[0025] Step S1 is used to make a template. Adding a margin area helps to ensure the uniformity of the thickness of the effective area in the center of the template after replication. The electroforming deposition rate around the template is higher than that in the middle area. Increasing the margin area can avoid inconsistent thickness caused by edge effects. In addition, the thickness of each template made by the original mold of the present invention can be inconsistent. When assembling, the front side can be flattened based on the front side, which reduces the difficulty of production. Step S2 is used to cut the cutting area and the position of the combined edge. Pre-cutting can reduce the subsequent trimming work required, shorten the processing time, and improve the overall processing efficiency. Pre-cutting belongs to rough processing, which can roughly trim the template in place and shorten the time for subsequent fine grinding. Step S3 is used to clamp and flatten the template to be combined. The template is flattened to the maximum extent to ensure that the subsequent combined edge is perpendicular to the prism surface after processing. Tighten the tooling to clamp the template to ensure that the template remains flat during subsequent processing and assembly, and avoid errors caused by bending or warping of the template. Through clamping and flattening operations, the precise alignment of the template edges is ensured, which helps to reduce the stress caused by uneven force during the processing and assembly of the template, and reduce the risk of cracking and deformation. The template to be assembled is clamped with a fastening fixture because the template is thin during the template duplication process, and the template will be slightly bent by force during the separation process, resulting in the prism matrix not being on the same plane. After clamping with a fastening fixture, the template can be leveled, and the ground combination edge in the subsequent grinding process will be perpendicular to the prism surface, which can ensure the tightness of the seam in the subsequent assembly process. Step S4 is used to finely grind the prism of the combination edge, and step S5 is used for laser welding, thereby achieving a tight and seamless combination.

[0026] Preferably, in the above-described method for seamlessly assembling a full prism mold, in step S1, a reference steel plate is used to increase a margin area, a window is opened on the reference steel plate, and the original mold is embedded therein, and the thickness of the manufactured template is 0.4 mm to 3 mm.

[0027] The use of the reference steel plate ensures the uniformity of thickness in the effective area of ​​the template center after replication, simplifies the fixing and positioning process of the original template, and improves processing efficiency. The template is made of thin plate, with a short production cycle and easy processing.

[0028] Preferably, in the above-mentioned method for seamlessly assembling a full prism mold, step S2 first measures with a microscope, and then uses a wire cutting device to cut according to the cutting area and the assembly edge position.

[0029] The use of a microscope can accurately measure the cutting position before cutting to ensure the accuracy of the cutting. Accurate measurement allows the wire cutting equipment to cut according to the predetermined precise path, improving the processing quality. The cutting area is used as a non-combined edge for post-processing to facilitate picking and welding reinforcement.

[0030] Preferably, in the above-described method for seamlessly assembling a full prism mold, when the template to be assembled is clamped in step S3, the assembly edges of the template to be assembled extend out of the fastening tooling by 0.5 mm to 1.1 mm.

[0031] The extension is good for observation, which helps to improve the alignment accuracy of the template during assembly and ensure the welding quality. The less extension, the better to keep the template flat and prevent it from bending due to gravity, thus ensuring the assembly quality.

[0032] Preferably, in the above-described method for seamlessly assembling a full prism mold, step S4 is first observed under a microscope and then finely ground with a precision grinder to remove the grooves so that the assembled edge has a complete prism when observed under a microscope.

[0033] Through microscopic observation and precision grinding, the grooves are trimmed to ensure the integrity of the prisms at the combined edge, avoid edge defects, and ensure the integrity of the prism reflective surface. The grooves are trimmed to leave a complete prism, so that when the templates are assembled, the weld at the combined edge after assembly will be consistent with the original prism groove, achieving a seamless combination. Secondly, since the reflective surface of the prism is an inclined surface, if the grinding position is on the prism, the width of the two sides is slightly inconsistent, which will cause the combination position to be high and low. In addition, if the prism surface is ground, the grinding process will also damage the reflective surface of the prism.

[0034] Preferably, in the above-described method for seamlessly assembling a full prism mold, in step S5, first place the fastening tool on the table, then observe it under a microscope, bring the fastening tool close, align the combined edges of the two templates to be combined, so that the combined edges are located at the observation window, and finally use a laser to perform seam welding on the back, and then perform seam welding on the cut area of ​​the combined edge on the front to obtain a seamless mold.

[0035] The above design ensures the alignment of the prism grooves. The precise alignment and seamless welding ensure the structural integrity of the mold and ensure quality. Seamless welding reduces optical distortion and improves the optical performance of the prism mold. The trimming area of ​​the front combination edge is supplemented with welding to further strengthen the combination connection of the combination edge.

[0036] Preferably, in the above-described method for seamlessly assembling a full prism mold, when the template to be assembled is clamped in step S3, a PET protective film is placed between the fastening tooling and the template to be assembled.

[0037] The PET protective film can prevent the fastening tool from directly contacting the template prism, thereby preventing scratches or wear on the template surface during the clamping process, helping to protect the optical surface and reducing the marks left by the fastening tool on the template. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 It is a structural schematic diagram of the present invention;

[0039] Figure 2 It is a schematic diagram of the top view of the structure of the present invention;

[0040] Figure 3 It is a schematic diagram of the local structure of the present invention;

[0041] Figure 4 It is a schematic diagram of the structure of the template in the present invention;

[0042] Figure 5 It is a schematic diagram of the structure of the prism area of ​​the template in the present invention under microscope observation. DETAILED DESCRIPTION

[0043] The following is combined with Figure 1-5 The present invention is further described in detail with specific embodiments, but they are not intended to limit the present invention:

[0044] Example 1

[0045] A seamless assembly mechanism for a full prism mold comprises a table top 1 and a fastening tool 2, wherein the fastening tool 2 is symmetrically arranged on the table top 1, a template area 3 is arranged inside the fastening tool 2, a combination area 4 is arranged between the fastening tool 2, and the table top 1 is provided with an observation window 5, and the observation window 5 cooperates with the combination area 4.

[0046] Preferably, the fastening tool 2 includes reference blocks 6 arranged in parallel up and down, and a template area 3 is formed between the reference blocks 6.

[0047] Preferably, tightening threaded holes 7 are symmetrically provided on both sides of the reference block 6, and the reference blocks 6 are threadedly connected.

[0048] Preferably, the table top 1 is a magnetic table top, and the fastening tool 2 is magnetically connected to the table top 1 .

[0049] Preferably, the template region 3 extends into the combination region 4 toward each other.

[0050] A method for seamlessly assembling a full prism mold, comprising any one of the seamless assembly mechanisms described above, and further comprising the following steps:

[0051] S1: Make the template, and add at least 10cm of margin area around the original mold during production;

[0052] S2: cutting the cutting area and the combined edge position of the template to obtain the template to be combined;

[0053] S3: Clamp and flatten the template to be assembled using the fastening tool 2;

[0054] S4: fine grinding the combined edge of the combined template;

[0055] S5: Bring the fastening tooling 2 closer, align the combined edges of the two templates to be combined, and use laser to perform seam welding on the back to obtain a seamless mold.

[0056] Preferably, in step S1, a reference steel plate is used to increase a margin area, a window is opened on the reference steel plate, and the original mold is embedded therein, and the thickness of the manufactured template is 0.4 mm to 3 mm.

[0057] Preferably, in step S2, a microscope is used for measurement first, and then a wire cutting device is used to cut according to the cutting area and the combined edge position.

[0058] Preferably, when the template to be assembled is clamped in step S3, the assembled edge of the template to be assembled extends out of the fastening tooling 2 by 0.5 mm to 1.1 mm.

[0059] Preferably, in step S4, the surface is first observed under a microscope and then finely ground with a precision grinder to remove the grooves so that the combined edge has a complete prism when observed under a microscope.

[0060] Preferably, in step S5, the fastening tool 2 is first placed on the table 1, and then observed under a microscope, the fastening tool 2 is moved closer, and the combined edges of the two templates to be combined are aligned so that the combined edges are located at the observation window 5, and finally a laser is used to perform seam welding on the back side, and then the cut area of ​​the combined edge on the front side is seam welded to obtain a seamless mold.

[0061] Preferably, when the template to be assembled is clamped in step S3, a PET protective film is placed between the fastening tool 2 and the template to be assembled.

[0062] The thickness of the template is 0.4 mm to 3 mm, which can be 0.4 mm, 1.7 mm, 3 mm. The thickness of the thick template on the market is generally above 7 mm.

[0063] Add at least 10cm of margin area around the original mold. The larger the margin, the better the effect. For cost considerations, it can generally be 10cm, 15cm, 20cm, or 25cm.

[0064] The combined edge of the template to be combined extends out of the fastening tooling 2 by 0.5 mm to 1.1 mm, which can be 0.5 mm, 0.8 mm, 1 mm, or 1.1 mm.

[0065] like Figure 4As shown, step S1 produces a template 100. The template 100 includes a prism area 101, a margin area 102, and a cutting area 103. The upper and lower sides of the prism area 101 and the cutting area 103 are combined edges 104. Multiple templates 100 are combined by aligning the combined edges 104 in sequence from top to bottom. The length and width of the prism area 101 are generally between 30 mm and 80 mm, and can be 30 mm, 55 mm, and 80 mm. The width of the cutting area 103 is generally between 4 mm and 6 mm, and can be 4 mm, 5 mm, and 6 mm.

[0066] In step S2, the prism area 101 and the cutting area 103 are cut, the surplus area 102 is cut off, and the prism area 101 and the cutting area 103 are left to obtain a template to be assembled. The cutting area 103 is used for later processing to facilitate picking. Avoid damaging the prism area 101.

[0067] In step S5, the combined edges 104 on the back of the two templates to be combined are welded first, and then the combined edges 104 on the front corresponding to the cutting area 103 are reinforced and welded. This can strengthen the welding connection of the two templates to be combined and avoid damaging the prism area 101.

[0068] like Figure 5 As shown, there are black grooves between the upper and lower rows of white prisms in the prism area 101. The grooves are generally 10μm to 20μm. In step S4, the black grooves at the combination edge 104 are removed, leaving only the white complete prisms. In step S5, after the two templates to be combined are combined, the weld at the combination edge 104 is consistent with the original prism groove in appearance, thereby achieving seamless combination.

[0069] In conclusion, the above is only a preferred embodiment of the present invention, and all equivalent changes and modifications made within the scope of the patent application of the present invention should fall within the scope of the present invention.

Claims

1. A seamless assembly mechanism for a full prism mold, characterized in that: The invention comprises a table top (1) and a fastening tool (2), wherein the fastening tool (2) is symmetrically arranged on the table top (1), a template area (3) is arranged inside the fastening tool (2), a combination area (4) is arranged between the fastening tool (2), and the table top (1) is provided with an observation window (5), and the observation window (5) cooperates with the combination area (4).

2. A full prism mold seamless assembly mechanism according to claim 1, characterized in that: The fastening tool (2) comprises reference blocks (6) arranged in parallel up and down, and a template area (3) is formed between the reference blocks (6).

3. A full prism mold seamless assembly mechanism according to claim 2, characterized in that: Tightening threaded holes (7) are symmetrically arranged on both sides of the reference block (6), and the reference blocks (6) are threadedly connected.

4. The full prism mold seamless assembly mechanism according to claim 1, characterized in that: The table top (1) is a magnetic table top, and the fastening tool (2) is magnetically connected to the table top (1).

5. The full prism mold seamless assembly mechanism according to claim 1, characterized in that: The template area (3) extends toward each other into the combination area (4).

6. A method for seamlessly assembling a full prism mold, characterized in that: The seamless combination mechanism according to any one of claims 1 to 5 further comprises the following steps: S1: Make the template, and add at least 10cm of margin area around the original mold during production; S2: cutting the cutting area and the combined edge position of the template to obtain the template to be combined; S3: Clamp and flatten the template to be assembled using a fastening tool (2); S4: fine grinding the combined edge of the combined template; S5: Bring the fastening tooling (2) closer together, align the combined edges of the two templates to be combined, and use laser to perform seam welding on the back to obtain a seamless mold.

7. A method for seamlessly assembling a full prism mold according to claim 6, characterized in that: In step S1, a reference steel plate is used to increase a margin area, a window is opened on the reference steel plate, and the original mold is embedded therein. The thickness of the manufactured template is 0.4 mm to 3 mm.

8. A method for seamlessly assembling a full prism mold according to claim 6, characterized in that: Step S2 first uses a microscope to measure, and then uses a wire cutting device to cut according to the cutting area and the combined edge position.

9. A method for seamlessly assembling a full prism mold according to claim 6, characterized in that: When the template to be assembled is clamped in step S3, the assembled edge of the template to be assembled extends out of the fastening tooling (2) by 0.5 mm to 1.1 mm.

10. A method for seamlessly assembling a full prism mold according to claim 6, characterized in that: Step S4 is to first observe with a microscope and then finely grind with a precision grinder to remove the grooves so that the combined edge has a complete prism when observed with a microscope.

11. A method for seamlessly assembling a full prism mold according to claim 6, characterized in that: Step S5, first place the fastening tool (2) on the table (1), then observe it under a microscope, move the fastening tool (2) closer, align the combination edges of the two templates to be combined, so that the combination edges are located at the observation window (5), and finally use laser to perform seam welding on the back side, and then perform seam welding on the cut area of ​​the front combination edge to obtain a seamless mold.

12. A method for seamlessly assembling a full prism mold according to claim 6, characterized in that: When the template to be assembled is clamped in step S3, a PET protective film is placed between the fastening tool (2) and the template to be assembled.

Images